Relativity’s first rocket is named the Terran. Powered by the liquid-oxygen (LOx) methane engine AEON 1 this vehicle, when complete, will be capable of transporting a payload of up to 1,250 kg to a low Earth orbit of 185 km. To high altitude, 1200 km/sun synchronous orbit, the rocket will be able to carry up to 700 kg.

The AEON 1 engine, which has already undergone over 100 test firings is composed of 100 components, a fraction of the number of parts for a typically produced engine; This part, as with a full 95% of the current Terran rocket, is built on the Stargate 3D printer.

Operated by robotic arms, the Stargate has an entirely salable build volume. One of the largest parts it has built so far is a fuel tank measuring 7 feet wide and 14 feet tall.

Relative to the output rate of the Stargate, Relativity estimates that it can 3D print an entire Terran rocket in under 60 days.

The Relativity Space Aeon Engine. Photo via Relativity Space.

Relativity’s machine learning patent

The most recent patent award to Relativity is for a machine learning process capable of automatically detecting and correcting faults within the additive manufacturing (or welding) process.

The method was invented by Ellis, Relativity CTO Jordan Noone and Edward Mehr, the Program Manager for Relativity’s Stargate system. It specifically pertains to the monitoring of a wire-fed metal 3D printing process, as opposed to powder bed additive manufacturing.

In order to create self monitoring, and correcting, capabilities within this 3D printing process, the team creates a software combining a four grouped data elements. Firstly, Finite Element Analysis (FEA) simulation data of the build. Secondly, in-situ laser beam interferometry data generated from probing the build. Third, post-build inspection data from previous jobs. And the fourth, unspecified, “other training data” allowing the machine to build its understanding.

By comparing its current job with all of this information, the 3D printer is programmed to take action should something seem incorrect. By doing so, the team ensures a smoother build, with less material wastage and potential failures.

To date, following $35 million Series B funding from 2018, Relativity has raised an estimated $45.1 million, some of which has been used to grow the company’s manpower. According to recent reports for the company, in the past year it has taken on 50 new members of staff, raising its employee base from 14 to 64.

The company’s most recent hires are Tim Buzza, Josh Brost and David Giger.

Buzza joins Relativity as Distinguished Engineer after an 8 month term as Advisor to the company. His career, which began in 1988, started with a 14 year term as Advanced Research and Development at Boeing, and went on to encompass senior roles at Space Exploration Technologies and Virgin Orbit.

Brost, is Relativity’s new Vice President of Government Business Development (which already includes a deal with the U.S. Air Force.) Brost joins the company following almost 9 years in a similar role at SpaceX.

And Giger, the former Senior Director of Dragon Engineering at SpaceX, is Relativity’s Vice President of Launch Vehicle Development for the Terran 1.

Aiming to maintain the momentum of its employee appointments ahead of the Terran’s first orbital laucnh in 2020, there are still several open positions available at Relativity HQ and its test facility in Mississippi.

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Beau Jackson is Senior Journalist at 3D Printing Industry. With a longstanding commitment to the site's content, she is credited with producing more articles than any other author in its history. Well-versed in the latest 3D printing research and legal/regulatory challenges, her repertoire spans aerospace, automotive, maritime, medical and creative industries. She is a keen speaker and active representative of the company at key additive manufacturing events.